Rotor Cooling Control for High-Speed Permanent Magnet Machines

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Solution Overview

Problem

Permanently excited electric machines used in generators, such as those in wind turbines, face issues with high pole wheel voltage at high rotational speeds, leading to potential damage, especially when permanent magnets are cold, and field weakening methods are limited in flexibility.

Innovation Solution

A rotor-cooling apparatus with a control device that independently adjusts cooling power through a fan or re-cooler system, allowing for temperature-dependent cooling of permanent magnets to reduce pole wheel voltage and prevent damage at high speeds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the electric machine is operated at high rotational speeds with cold permanent magnets, then the pole wheel voltage increases significantly, but this leads to damage risk in the converter

Engineering Contradiction:
Improverotational speedVSAvoidconverter damage risk
Core Design Contradiction:
SpeedVSReliability

Solution Approach 1:

The patent changes the temperature parameter of the permanent magnets by implementing a heating device that raises the magnet temperature from cold operating conditions (e.g., -20°C) to a controlled temperature range (e.g., 20-80°C). This parameter change reduces the pole wheel voltage significantly, allowing high rotational speeds to be operated without damaging the converter.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If field weakening is used to limit terminal voltage, then converter damage is prevented, but the method reduces flexibility in operation

Engineering Contradiction:
Improveconverter protectionVSAvoidoperational flexibility
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies preliminary action by heating the permanent magnets before high-speed operation begins. The heating device is activated in advance to raise the magnet temperature to an optimal range, thereby pre-conditioning the system to operate at high speeds without requiring restrictive field weakening control during operation. This maintains operational flexibility while ensuring converter protection.

Inventive Principle:
Principle #10Preliminary action

3Reliability

If the electric machine is designed with a small number of windings to generate low pole wheel voltage, then converter damage is prevented, but the power factor decreases

Engineering Contradiction:
Improveconverter protectionVSAvoidpower factor
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

Instead of changing the winding configuration, the patent changes the temperature parameter of the permanent magnets. By heating the magnets to an optimal temperature range, the magnetic flux strength is optimized, allowing the machine to maintain a good power factor with the existing winding design while still operating at high speeds without damaging the converter.

Inventive Principle:
Principle #35Parameter changes

4Temperature

If a cooling device is used to cool the rotor, then the permanent magnets are cooled, but this increases the pole wheel voltage at high speeds

Engineering Contradiction:
Improvepermanent magnet temperatureVSAvoidrotational speed
Core Design Contradiction:
TemperatureVSSpeed

Solution Approach 1:

The patent inverts the conventional cooling approach by implementing a heating device instead. Rather than cooling the permanent magnets to improve efficiency, the system heats the magnets to reduce pole wheel voltage, thereby enabling high rotational speeds without converter damage. This inversion of the temperature control strategy resolves the contradiction between magnet temperature and speed capability.

Inventive Principle:
Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables reliable operation of electric machines at high rotational speeds by controlling the cooling of permanent magnets, reducing the risk of damage and optimizing power factor, while allowing for flexible operation without excessive rotational speed limitations.

Implementation Method 1

a heating device for heating the permanent magnets

Methodology Applied
Scientific EffectHeating: Heating

Implementation Method 2

the rotor-cooling apparatus has at least one cooling device for providing a cooling-air flow

Methodology Applied
Scientific EffectForced Convection: Forced Convection

Data Source

PatentUS11371488B2Electric machine with independent rotor cooling device, generator arrangement and wind turbine
Publication Date: 2022.06.28 FLENDER GMBH
  • US11371488B2 patent drawing
  • US11371488B2 patent drawing
  • US11371488B2 patent drawing

AI summary

The invention relates to an electric machine (2) comprising a stator (2) and a rotor that can rotate relative to the stator (2), the rotor (3) having a plurality of permanent magnets (5), also comprising a rotor cooling device (8) for cooling the rotor (3), wherein the rotor cooling device (8) comprises at least one cooling device (23) for providing a cooling air flow, said rotor cooling device (8) comprises a control device (22) which is designed to control at least one cooling device (23) for adjusting a coolant power provided by the cooling air flow.